Visual Safety Module With Predictive Braking for Processing Machines
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Solution Overview
Problem
Existing processing machines, such as sawing tools, pose a risk of harming operators due to accidental activation or entry into the danger zone, necessitating improved safety mechanisms.
Innovation Solution
A safety module comprising a visual element that defines safety and danger zones, a brake, and a controller to manage power source operation, preventing accidental start-up and stopping the power source when an object enters the danger zone or is at risk of entering it, using biometric or non-biometric targets for recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a visual element and controller are added to prevent accidental activation and detect danger zones, then safety protection is improved, but device complexity increases
Solution Approach 1:
The visual element performs preliminary recognition of the specific target (biometric or non-biometric) before the power source is activated. The controller is programmed to require this recognition as a prerequisite for operation, preventing accidental activation. This preliminary safety check is integrated into the startup sequence without requiring complex additional hardware.
Solution Approach 2:
The controller acts as an intermediary between the visual element and the power source/brake. It receives signals from the visual element regarding target recognition and danger zone detection, then translates these into appropriate control actions (preventing startup or activating the brake). This intermediary role simplifies the overall system architecture by centralizing the logic.
2Reliability
If the brake is activated immediately when an object enters the danger zone, then operator safety is improved, but operation time is reduced
Solution Approach 1:
When the visual element detects an object entering the danger zone, the system rushes through the safety protocol by immediately activating the brake without delay. This rapid response prioritizes operator safety over operational continuity, ensuring the processing member stops before contact can occur.
Solution Approach 2:
The visual element continuously monitors the workspace and provides real-time feedback to the controller about object positions relative to the danger zone. This feedback loop enables the system to respond dynamically to safety conditions, activating the brake only when necessary while maintaining normal operation otherwise.
3Reliability
If biometric recognition is used to verify operator presence, then safety control is improved, but measurement precision requirements increase
Solution Approach 1:
The system uses biometric or non-biometric target recognition as a partial safety measure rather than requiring perfect identification. The controller is programmed to accept various forms of recognized targets (different biometric features or non-biometric objects) to trigger safe operation, providing sufficient safety control without demanding extremely high measurement precision.
Data Source
AI summary
A safety module, which is applied to a processing machine including a processing member and a power source connected with the processing member, includes a visual element, a brake and a controller. The visual element defines safety and danger zones for the processing scope of the processing member. The brake is connected with the power source for providing a brake effect to the power source. The controller is connected with the power source, the visual element and the brake. When capturing that an object is located in the danger zone or determining that an object is about to enter the danger zone according to the movement trajectory of the object, the visual element transmits a brake signal to the controller to make the controller drive the brake to control the power source to stop operating. The safety module improves the safety of the operator operating the processing machine.